Abrasive-Waterjet Machining Of Composites

Transcription

DECEMBER 2008
Published by the
WaterJet Technology Association
for the benefit of its members
906 Olive Street, Suite 1200 l St. Louis, MO 63101-1448, USA l Telephone: (314)241-1445, Fax: (314)241-1449
Abrasive-Waterjet Machining Of Composites
AWJ-drilled holes in a carbon fiber composite panel.
See article by Mohamed Hashish, Ph.D., on page 2
2009 American WJTA Conference and Expo, Details inside
August 18-20, 2009
l
Houston, Texas, USA
Abrasive-Waterjet Machining Of Composites, from page 1
By Mohamed Hashish, Ph.D., Member – WJTA, Flow International Corporation, Kent, Washington 98032
Abstract
The use of carbon fiber composites
is significantly increasing as a
structural material for commercial
airframes. This material represents
50% by weight for the new Boeing
787 and Airbus 350XWB frames.
The Abrasive-Waterjet (AWJ) has
been the tool of choice for trimming
and shapecutting this material due to
many technical, environmental, and
economical reasons. The AWJ cuts
are of acceptable surface finish and
of high integrity. The cutting rates
are faster than conventional routing.
Significant advances have been made
in the hardware, software, and the
AWJ process reliability, flexibility,
and productivity placing the AWJ
process as a mainstream tool for
airframe manufacturers and their
subcontractors.
1. Introduction
The use of advanced materials such
as composites has been escalating
rapidly over the past three decades,
especially in the aerospace industry,
coincident with the introduction of
AWJ technology to the marketplace
in the 1980s. In fact, the use of
waterjet technology in aerospace
applications has a significant impact
on its advance in meeting reliability,
flexibility, and productivity demands.
This article briefly discusses the AWJ
hardware, software, and routinely
used machining processes such as
trimming and drilling for carbon fiber
composites.
jet engine and air frame components.
In jet engine for example, the engine
cold section will incorporate OMCs,
MMCs, and intermetallics. OMC
components may include fan frames,
fan blades, inlet and outlet guide
vanes, stator vanes, cases, and control
housings. Graphite-PMR-15 structural
parts are used on such engines as
GE F110 and F404, and PW-1120
and 1130. Hot sections, such as
combustors and turbine exhaust,
will require the high-temperature
capabilities of some intermetallics,
single-crystal superalloys, CMCs, or
carbon/carbon composites.
The use of OMCs, especially
carbon-fiber based composites for
aerostructures, have been initially used
on military airframes. Now carbon
fiber composites are used extensively
on commercial aircraft. Example parts
are:
• Wing: Covers, Spars, Leading
Edges, Flaps
• Fuselage: Panels, Stringers,
Frames, Clips, Doors
• Tail: VTP & HTP Covers, Rudder,
and Flaps
• Keel Beam, Centre Wing Box,
Belly Fairing
The following are example aircraft
and corresponding AWJ-machined
components:
• Boeing 787 - center wing box,
wing skins, spars, stringers, fixed
leading edge, vertical stabilizer,
777 – horizontal stabilizer, 747 titanium landing gear components
- see Figure 1 below
• Airbus 350XWB – wing spars
• Bell Helicopter V-22 Osprey wing skins, stiff rotors
• Raytheon Premier I – The fuselage.
The most common AWJ-cut carbon
fiber composite parts in an air frame
are found in:
Most revolutionary in the use of
composites on commercial liners is
the Boeing 787 which will contain
50% composite structure by weight
and 90% by volume and the Airbus
A350XWB with similar composite
usage. In comparison, the 777, which
(continued on page 12)
1.1 Composite Systems
Composites used in the aircraft
industry could be organic, metal, and
ceramic matrix composites (OMCs,
MMCs, and CMCs). These are used in
Page 2
Figure 1: 777 Tail Fin Composite Structures
WJTA on the web: www.wjta.org
December 2008
Nominations Open For WJTA Board of Directors
N
ominations for the WaterJet Technology Association (WJTA) Board of Directors are now open,” says WJTA
Secretary Hugh B. Miller, Ph.D. “The duties of the directors
are truly challenging and rewarding.”
The terms of office of Greg Galecki, Ph.D., Mohamed
Hashish, Ph.D., Hugh B. Miller, Ph.D., Bill McClister, George
A. Savanick, Ph.D., and B.T. Steadman will expire in August
2009. Therefore, nominations are sought for six (6) board
members, each to serve a four-year term of office beginning
August 17, 2009.
The WJTA bylaws provide that no more than one of the
elected board members may be from the same company
or organization. Therefore, board members may not be
nominated from the same company or organization already
represented on the board by individuals whose terms expire
in 2011, including DeBusk Industrial Services Company (Pat
DeBusk), High Pressure Equipment Company (Larry Loper),
NLB Corporation (Forrest A. Shook), StoneAge, Inc. (John
Wolgamott), Environmental Solutions Group/Federal Signal
(Bill Gaff), and Polyflex Business Unit/Parker Hannifin
Corporation (Paul Webster).
Nominations/Elections Procedures
In accordance with the bylaws of the WaterJet
Technology Association, nominations and elections to the
Board of Directors include the following procedures:
 At least two calls for nominations to the board of
directors will be published in the Jet News. The
first call for nominations appears in this issue.
Nominations will be accepted through March
31, 2009.
 An official ballot listing the eligible nominees and
a brief biographical sketch for each individual will
then be forwarded by mail to all eligible voting
members of the Association on May 28, 2009.
Signed and executed ballots must be mailed to
the Association’s office for tallying by June 25,
2009.
 The names of newly elected board members will
be announced in the Jet News and on the WJTA
web site.
Only WJTA members in good standing (2008 membership
dues paid) may submit a nomination(s). A nominee who
has not paid his/her dues by March 31, 2009, shall be
declared ineligible to run for office in the 2009 election.
According to the WJTA bylaws, any WJTA member in
good standing (2008 membership dues paid) may submit a
nomination(s). A nominee who has
not paid his/her dues by March 31,
Nomination Form
2009, shall be declared ineligible to
Name of Nominee____________________________________________________________
run for office in the 2009 election. The
Title_______________________________________________________________________
deadline for making nominations is
Address____________________________________________________________________
March 31, 2009. Your nomination(s)
should reach the WJTA office no later
City_____________________________________________ State______________________
than March 31, 2009.
Country ____________________________________________ Postal Code_____________
To submit a nomination(s),
complete the Nomination Form and
return, along with biographical
information and a brief statement of
your nominee’s mission and vision for
WJTA, to:
Telephone______________________________ Fax________________________________
Email______________________________________________________________________
Attach biographical information with a brief statement
of your nominee’s mission and vision for WJTA.
Name of Nominator___________________________________________________________
Title_______________________________________________________________________
WJTA Administrative Office
906 Olive Street, Suite 1200
Saint Louis, MO 63101-1448
Phone: (314) 241-1445
Fax: (314) 241-1449
Address____________________________________________________________________
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Remember, nominations must be
received no later than March 31, 2009.
Page 4
Return completed Nomination Form and supporting information to:
WJTA Administrative Office, 906 Olive Street, Suite 1200, Saint Louis, MO 63101-1448
December 2008
G.O. H2O Attributes Continued Growth to Diverse Markets
Edmonton Waterjet Shop Experiences Nine Straight Years of Growth
W
hen Garnett Gerke opened his Edmonton, Alberta, waterjet
shop, G.O. H2O, more than ten years
ago, he deliberately decided to target
diverse markets rather than hinge his
fate on a niche industry.
This approach has served G.O. H2O
well. The company has grown every
year for the past nine years, and even
added a second waterjet table last year
to keep up with demand.
“We attribute our growth to
Alberta’s strong oil and gas-based
economy, but also to the fact that
we market to other areas such as
architectural, glass, flooring, metal
fabricating and a small amount in
plastics,” Gerke noted.
Page 6
Gerke credits his former
business partner for coming
up with the idea of opening
a waterjet shop. His partner
got the idea while working
on a road construction crew
in northern Alberta. The
crew ran into challenges
trying to drill through rock
so he went online to research
the idea of cutting material
with something more
innovative and efficient than
coring methods. After some
research, he determined that Garnett Gerke of G.O. H2O, Edmonton, Alberta.
waterjet was the wave of the
future in terms of cutting,
of the world,” yet the city only had
and also found that Edmonton was
one waterjet shop at that time.
considered the “machine shop capitol
December 2008
Edmonton Waterjet Shop Experiences Nine Straight Years Of Growth, from page 6
Gerke’s 12 years in the trades as a
cabinetmaker coupled with four years
of marketing experience came in
handy as the men built their business.
They decided to focus primarily on
waterjet cutting rather than machining
since the area was saturated with
machine shops.
“When we did have downtime, Jet
Edge’s customer service was amazing,
even on holidays,” he added. “On
one of the rare times our system went
down, it went down over the U.S.
Thanksgiving holiday, which is not
a holiday for us. I called Jet Edge’s
emergency service contact, and they
went in and shipped the part out. We
were back up and running for the
weekend.”
After more than ten years of positive
experiences, Gerke said he would
When they bought their first waterjet
table, they chose a 4x12-foot High
Rail Gantry manufactured by Jet Edge,
Inc. of St. Michael, Minnesota. They
equipped the table with two cutting
heads and powered it with a 100hp,
55,000 psi (4,100 bar) Jet Edge 55-100
intensifier pump with dual intensifiers.
“We liked the idea that Jet Edge was
a privately owned company versus
a publicly traded company,” Gerke
said. “We also liked their reputation of
quality.”
G.O. H2O had racked up nearly
35,000 hours on its first system when
Gerke and his new business partner,
Don Torok, decided to buy a second
system.
For the second system, the company
went with a 6x12-foot Jet Edge
High Rail Gantry so they could
accommodate larger sheet sizes. They
equipped this system with two cutting
heads and a 55-100 Jet Edge intensifier
pump. Both waterjet systems are
equipped with overhead cranes, and
Gerke noted that the tables are very
easy to load by crane or forklift.
“When it was time to buy the second
machine, it was very tempting to look
at the other manufacturers, and we did,
but how can you argue with 35,000
hours and very little downtime,”
Gerke said, noting that on his original
ten-year-old pump, he has only had
to replace one of the intensifiers. The
electric motor and one intensifier are
still original.
December 2008
Page 7
Flow Opens New
Cutting Hollow Structures
Czech Republic
any applications in waterjet Sales and Customer
cutting are involved
Service Center
with hollow structures.
M
F
low International Corporation has announced the opening of
a new sales and customer service
center in the Czech Republic. The
new center, located in Brno, Czech
Republic, will serve customers in
central and Eastern European markets,
including Croatia, Slovenia, Hungary,
Romania, Poland, Czech Republic,
Slovakia, Russia, Belarus, and the
Ukraine. The center was opened in
response to the growth of Flow’s
European customer base in those
countries and the future growth
opportunities in these countries.
“As a result of the increased demand
for waterjet cutting technology
worldwide and Flow’s growing
European customer base, we seized
the opportunity to open a sales and
service center to best serve our Eastern
European customers,” said Charley
Brown, CEO, Flow International.
“The new center will complement our
European headquarters in Bretten,
Germany so Flow can continue to
deliver the highest possible service to
our growing European customer base.”
For more information, visit www.
flowcorp.com.
WJTA 25th
Anniversary
1983-2008
Page 8
The hollow space tends
to disperse the jet and
affects the cut below.
Louis & Von Rad* did
an experimental study
on this phenomenon.
Here is a review of their
findings.
Their experimental
setup to simulate a
hollow structure is
illustrated in the top
figure. Cutting tests
were done on aluminum
with a 1-mm abrasive
water suspension jet at
70 MPa of pressure and
2 kg/min of 80 mesh
garnet. The parameters
were chosen so that the
sample below the gap
was not cut through in
order to preserve the
evidences of remaining
jet potential. The gap
was filled with either
air or water to study the
impact of medium. The
results were plotted in
the other two figures.
The reduction of
the kerf depth and
the increase of the
kerf width on the sample were
proportional to the size of gap.
Compared to air, water made
the kerf shallower and narrower
because the outer layer of the jet
lost energy to the surrounding
water. It was also found that the
thickness of the upper plate had
a small impact to the kerf-depthvs- gap-size relation (i.e., a thicker
upper plate resulted in a shallower
kerf), but a relatively large impact
to the kerf-width-vs-gap-size relation
(i.e., a thicker upper plate resulted in
a wider kerf). The explanation was
that the upper plate acted as a “bad”
nozzle.
*Louis, H. & Ch Von Rad (2000), “Cutting
of hollow structures with abrasive water
suspension jets,” in Proceedings of the
15th International Conference on Jetting
Technology, Ronneby, Sweden, September
6-8, pp59-67.
Reprinted by permission from Quality
Waterjet Newsletter, October 7, 2008.
December 2008
Personnel Appointments
• Jet Edge, Inc., has announced the
appointment of Eric Magnuson as
its new North Central regional sales
manager. Magnuson is responsible
for sales of Jet Edge waterjet
systems in Minnesota, North and
South Dakota,
Wyoming,
Nebraska,
Western Iowa,
Northern
Wisconsin and
Manitoba. He
brings to Jet
Edge more than
Eric Magnuson
10 years of
experience in
capital equipment sales. Magnuson
has a mechanical engineering degree
from the University of Minnesota.
He is based in St. Michael,
Minnesota, and can be contacted
at phone: (612)963-0933 or email:
ericm@jetedge.com.
has traveled extensively throughout
the world and has established
OEMs, dealers, and distributors in
approximately 35 countries on six
continents. In 1997, the governor of
Minnesota recognized Anderson’s
efforts and the company that he
worked for at the time with the
“Exporter of the Year Award.”
Anderson is based in St. Michael,
Minnesota, and can be contacted at
(763)497-8718 or sales@jetedge.com
• SPIR STAR Ltd. appointed a
new sales representative, Willie
Whittington, in September.
Whittington has over five years
of inside sales experience. His
primary responsibilities will be to
assist in the development of SPIR
STAR’s sales strategies and to help
maximize customer satisfaction and
performance. For more information,
visit www.spirstar.com or call
(281)664-7800.
IMPORTANT NOTICE REGARDING SPAM
Email addresses and other member contact information published in the WJTA Membership
Directory is meant to encourage helpful, informative communication between members. The
information is not provided to circulate spam or junk mail.
The WJTA leadership requests that members respect the contact information of fellow members and not use that information for the dissemination of spam or junk email. Membership
information is not meant to be circulated beyond the WJTA membership.
• Jet Edge, Inc., has also announced
the appointment of David J.
Anderson as its new international
sales manager. Anderson is
responsible for
export sales
of Jet Edge
waterjet UHP
pumps and
systems. He
brings to Jet
Edge 15 years
of experience
David J. Anderson
in sales
management,
marketing, training and customer
service in international and
domestic business sales. Recently
Anderson was an advisor to U.S.
and foreign businesses regarding
risk management, sales process,
and marketing management. He
has previous experience in sales
and marketing management with
specialized water pump capital
equipment manufacturers. Anderson
December 2008
Page 9
Select FS Solutions Centers Now Offer StoneAge Service And Repairs
T
o better serve industrial cleaning contractors, plant customers and
other industry professionals, Federal
Signal Environmental Solutions
Group has announced that the FS
Solutions centers in Toledo, Ohio
and Long Beach, California, are
authorized repair and service centers
for StoneAge brand waterblasting
and sewer cleaning tools, parts and
accessories.
“At FS Solutions, we are proud to
offer the kind of dependable products,
parts and services – like the StoneAge
line of waterblast tools – that our
customers need to get the job done,”
said Bryce Mulligan, rental manager
for FS Solutions. “We are also proud
that the technicians at our Toledo and
Long Beach centers have the training
and expertise to repair and rebuild
StoneAge products locally, rather than
requiring customers to rely solely
on the StoneAge service location in
Durango, Colorado.”
Page 10
“There is physics behind how you
make a water-spin tool and how you
jet it,” said Bill Shires, vice president
of sales and marketing for StoneAge.
“The technical sales specialists at FS
Solutions have been fully trained by
StoneAge engineers and are uniquely
suited to answer customer questions
about which StoneAge tools to use to
remove specific materials in specific
applications. FS Solutions also has
the necessary machining expertise and
tooling capabilities to repair our high
tolerance tool components.”
StoneAge products include the
Hurricane® 3D vessel and tank
cleaning tool, the Barracuda® 20,000
and 40,000 psi rotary nozzles and
Warthog® sewer cleaning tools. “We
are committed to building great
tools,” Shires said. “The location
of the StoneAge factory is far from
our customers’ job sites. Having
authorized repair locations minimizes
shipping costs and time for everyone.
We want our tools back in the
operator’s hands with the least amount
of downtime as possible.”
Since 1979, StoneAge, Inc.,
Durango, Colorado, has been a leading
provider of high-pressure waterblast
cleaning solutions. StoneAge products
are used in a variety of industrial
cleaning applications, including power
plants, refineries, pharmaceutical
companies and shipyards.
For more information about
StoneAge products and services,
call (866)795-1586, or visit www.
stoneagetools.com.
For more information about products
and services available from the FS
Solutions centers or to find the nearest
location, call (800)627-3171, ext. 298,
or visit www.federalsignal.com.
December 2008
2009 American WJTA
Conference and Expo
Tuesday-Thursday, August 18-20, 2009
Marriott Houston Westchase, 2900 Briarpark Drive, Houston, Texas 77042
•
Live, Onsite Demonstrations of a variety of waterjet applications (including
•
Waterjet Expo featuring displays of waterjetting equipment, systems and
•
Waterjet Boot Camp—Industry experts offer information and suggestions on
ways to help contractors buy smart, improve efficiency and generate profitable
new business.
•
Pre-Conference Workshops
s Waterjet Technology - Basics and Beyond
s Vacuum Equipment Safety Seminar
•
Emerging Technology, New Applications—Hear some of the world’s
foremost engineers and researchers share new developments in applications,
mechanics, equipment, and procedures.
cleaning, paint/coating removal, concrete preparation and testing of the
effectiveness of safety equipment) and industrial vacuum/air moving operations.
supplies and industrial vacuum/air moving vehicles.
The WJTA Conference and Expo is unique in that the program is dedicated to
high pressure waterjet technology and related industries. If you are involved in
high pressure waterjetting for cleaning, surface preparation, industrial vacuuming/
air moving for industrial cleanup/recovery, waterblasting or cutting, or if you are
interested in finding out more about the industry, the WJTA Conference and
Expo is an ideal resource for information and an excellent meeting for networking
with other professionals in the field.
Hotel Reservations at the Marriott Houston Westchase. The Marriott Houston
Westchase, 2900 Briarpark Drive, Houston, Texas 77042, is the central location for
the WJTA Conference and Expo activities. The Marriott is a smoke-free facility.
For reservations, call toll-free 800-452-5110 or contact the Marriott directly at
713-978-7400. Be sure to identify yourself as attending the WaterJet Technology
Association Conference to receive the special group rates of $149 single/double
occupancy. August 2, 2009, is the deadline for guaranteed room availability.
Reservations received after August 2, 2009, will be confirmed on a space
available basis. Rooms may still be available after August 2, but not necessarily at
the rates listed above.
Visit www.wjta.org for Conference information or contact:
WJTA, 906 Olive Street, Suite 1200, St. Louis, MO 63101-1448
Phone: 314-241-1445, Fax: 314-241-1449, Email: wja@wjta.org
December 2008
Page 11
entered service just over ten years
ago, contains only 10% composite
structure by weight. The military’s
new F-35 Lightning II (JSF) expected
to enter service in 2010 will have just
below 40% composite structure by
weight as Titanium Graphite (TiGr)
laminates will be used. The F-22
Raptor, which entered service in 2003,
has approximately 25% composite
structures by weight. Figure 1 above
shows the 777 tail fin with shaded
areas being carbon fiber composite
while Figure 2 shows the composite
parts on the 787.
Typical problems that have been
encountered when machining carbon
fiber composites with conventional
solid tools are matrix cracking,
fiber pullout, inter-laminar voids,
delamination, and resin melting.
This leaves frayed or delaminated
edges which require costly rework
and slowdown of
production cycles.
Frequent tool change
is required when
using routers or
drills due to the
abrasive nature
of the composite.
Environmentally,
solid tools generate
dust and carbon
powder which can
Figure 2: Materials Used in the Boeing 787 Aircraft
wreak havoc on
electrical systems and
several advantages over conventional
personnel.
machining methods. Among these
advantages are:
The above mentioned growing use
of composite materials on primary
aircraft structures requires technology
offering lower manufacturing and
tooling costs, and the reduced potential
for product defects. For 2D and 3D
cutting and machining of composite
structures, AWJ technology offers
• No distortion due to limited
jet forces and its nature of
micromachining action
• No heat affected zones
• Higher cutting speeds than routers
WATER JETTING SYSTEMS
281-448-5800 • FAX: 281-448-7500
1-800-231-3628
www.waterjetting.com • mktg.wjs@gardnerdenver.com
Page 12
December 2008
•
•
•
•
•
•
Reduced fixturing and tooling
No delamination
No subsequent processes are needed.
No splintering or fraying edges
Process automation and multi-operations are possible
No dust
In the following sections we describe some advances in
composite machining.
2. AWJ Technology Advances for
Composites Machining
There have been many advances in composites machining
with AWJ for air frames that can be grouped into two basic
categories. These are machinery (hardware) process, and
software advances. The following are descriptions of some
of these advances.
Figure 4: Hybrid Waterjet System
(Waterjet on the left, outer on the right)
2.1 Hardware:
2.1.1 Cutting Heads
The use of vacuum assist in AWJ cutting heads, see
Figure 3, has been critical for successful shapecutting of
composites. An external vacuum source is used to draw
abrasives into the cutting head before starting the waterjet.
This insures an
instantaneous
action of the
AWJ upon firing
the waterjet and
impacting the
Figure 3: AWJ Cutting Head with
material. It has
Vacuum Assist. One port is for abrasive
feed and the other for attaching vacuum
been shown that
delimitation does device.
not occur when
piercing composites using this approach. The vacuum
assist is particularly important when lower pressures are
used as often is the case when piercing composites. In this
case, the waterjet venturi effect is not sufficient to draw
abrasives reliably into the cutting head and thus vacuum
assist enhances the reliability of the AWJ process.
such as the one shown in Figure 5. Please note that a
small catcher is provided on a 6th axis for catching the exit
jet and directing the waste outside of the wrist area to the
collection tank. The router, see Figure 5, is used to drill
and counter sink the required holes or trim some critical
areas not easy to address with the AWJ. This system
provides significant advantage in minimizing set-up time.
Machines range in size from 10 ft to 150 ft in length with
width up to 50 ft. Probing and linear scales are used for
obtaining the required accuracy.
2.1.2 Hybrid Waterjet System
2.1.3 Flexible Fixturing
In order to trim and rout composites, both waterjets and
solid tool routers have been incorporated on special hybrid
systems as shown in Figure 4. In these systems, two 5-axis
masts are used: one for the AWJ and another for the router.
The AWJ is used to trim the part using an end effector
Flexible fixturing is a key component in AWJ machining
cells due to the wide variety of shapes and contours of
airframe parts. FLOW has developed versatile fixtures
consisting of a number of linear actuators with vacuum
December 2008
waterjet
Wrist
router
Wrist
Figure 5: AWJ and Mechanical End Effectors
Page 13
cups as well as hard location surfaces
and points for accurately locating
the part and rigidly holding it during
cutting. The fixture must also
accommodate the catcher and be
specific to the waterjet nature as a
long effective beam after penetrating
the material. Figure 6 shows a fixture
example for holding a wide range
of curved parts as may be used in
fuselage sections.
used for airframe are
trimming, shapecutting,
and drilling. Trimming
is typically performed
on the edges while
shapecutting is
performed on the
interior surfaces to
produce openings
such as access holes or
windows.
2.2 Software
2.3.1Trimming and
Shapecutting
Most airframe parts are designed using
CATIA solid modeling software. In
order to develop a CNC program to
trim and drill parts, a post processor
program is needed to translate the
drawing such that the machine
controller can execute it. This post
processor also includes information
about the process such as cutting
speed, tool diameter, etc. This is
a most critical element of the AWJ
machining system as most parts
are complex 3-D shaped. Flow
International and CINET Systems
developed FlowTrim: CAD (Data
Import, Part Design, Fixtures, Run-off
material), and CAM (Programming,
simulation, tool path modification, …)
as an integrated post processor using
integrated cutting technology models
and data tables. Figure 7 shows an
example screen with the end effector
and catcher displayed.
2.3 Waterjet Processes
The most common waterjet processes
Significant work has
been done on the use of
waterjets and abrasivewaterjets for composite
parts trimming.
This trimming is
required as parts are
typically oversized
Figure 6: Example Fixture for Holding Curved
due to the composite
Parts
manufacturing process.
A wide plateau of
parameters has been
found acceptable for
cutting wide range
of thicknesses - (0.1
inch to 3-inch)
sections of graphite
epoxy. The cut
surfaces of better
than 400 micro
inches (as typically
specified by Boeing)
are achieved at
relatively high
Figure 7: FlowTRIM® Software Screen by CINET
productivity levels. showing AWJ trimming end effector
For example, a
Safety Committee Solicits Comments On Improvements To Recommended Practices
T
he WJTA Safety Committee hereby solicits comments regarding improvements to the publication, Recommended Practices for the Use of Manually Operated High Pressure Waterjetting Equipment. While Recommended Practices
is reviewed periodically at the biennial conferences of the WaterJet Technology Association, your comments and suggestions for improving the publication are invited and welcome anytime.
Please address your comments and suggestions to: Safety Committee, c/o WJTA, 906 Olive Street, Suite 1200, St.
Louis, MO 63101-1448, phone: (314)241-1445, fax: (314)241-1449, email: wjta@wjta.org, web site: www.wjta.org.
Page 14
December 2008
cutting speed of 20 inch/min can be used
to trim a 0.35-inch thick carbon fiber
using a 0.010 inch AWJ at 55 ksi.
Figure 8. Composite Trimming and Shapecutting Examples
Some edges may be trimmed at bevel
angles, and when cutting around curves
and complex contours, the effective
depth of jet cutting varies and thus
waterjet kinematics parameters such as
speed and angles need to be carefully
programmed to maintain uniform edge
a. Composite Stringer
quality. Trimming I-Beam (stringer)
composites requires special tooling
such as catchers and cutting heads.
Figure 8-a shows a cross section of a stringer
with the top flange trimmed at 90 degrees with
an AWJ. The bottom flanges show the condition
of the edge before trimming. Figure 8-b shows a
trimming overview example for the 787 aircraft
stringers. The top and bottom flanges are shaped
trimmed with the ends trimmed to the center rib
or very close to it. Also, the bottom flange needs
to be beveled at about 45 degrees. Some access
holes are also drilled in the rib. These stringers,
especially the ones used in the wings are
c. Access Hole drilling relatively long, over 130-ft, and thus they require
at the root of a wing special machinery to handle them during cutting. box stringer
Shapecutting requires the piercing of a starting
hole. Some systems use a mechanical drill to pre-drill the
starting holes but most commonly now, AWJ is used to drill
b. Required Trimming of Stringer flanges and ends
d. AWJ trimming and cutting of complex 3-D composite wing part
Guzzler Reintroduces Predator™ Liquid Vacuum Tanker
G
uzzler Manufacturing has announced the reintroduction of
the Predator™ liquid vacuum tanker
designed for handling bulk liquids,
sludge and semi-solid waste in
industrial applications.
“With the relaunch of the
Predator, a full line of industrial
vacuum trucks is now available
from Guzzler Manufacturing,
complete with the parts, service,
training and industry expertise
you expect from the Guzzler
brand,” said Tim Lee, product
manager for Guzzler.
December 2008
The liquid vacuum tanker
combines high vacuum and pressure
offloading designed to deliver reliable
performance in the most demanding
applications. The 3,000 gallon payload
capacity tanker features a standard
vacuum pump capable of suction
pressures up to 27-29 inches Hg;
maximum airflow of more than 400
CFM and more than 300 CFM at 18
inches Hg. Alternate pump sizes
are also available.
The Predator’s single
compartment tank is constructed
with carbon steel and is rated
for continuous maximum
vacuum operation and 15 psi
working pressure. Built in
accordance with Section VIII of
Page 15
these holes as part of the shapecutting
sequence. In this case, vacuum assist
nozzles are used to mitigate risks of
delamination. Figure 8-c shows holes
drilled at the root of a stringer rib. In
order to cut near the bottom flange,
a special minimal-size AWJ nozzle
is used. The example trimming and
shapecutting shown in Figure 8-d is
quite complex due to the 3-D nature
of the trimming in different planes.
The design of a holding fixture in this
example is of critical importance.
While the majority of trimming
applications addresses relatively thin
sections (less than 0.75 inch), there
are several thick section (up to 3-inch)
cutting applications near the wingto-fuselage joining areas. Figure 9
shows example cuts in thick composite
sections which were found to be faster
than a mechanical tool by an order of
magnitude using much less demanding
fixtures and heavy equipment.
Figure 9: AWJ-Cuts in Thick
Composite Section
structures as shown in Figure
11. Cutting this class of materials
introduces additional challenge as the
cutting path is not continuous. A cut at
the bottom of a honeycomb structure
appears as a series of punched
holes. Cutting at a lead angle (a few
degrees) has been found effective for
minimizing this effect as shown in
Figure 12.
2.3.2 Drilling (Piercing)
Delamination is the main mode of
failure when drilling materials such
The end trimming of composite
stringers (I-beams) is another
application that requires careful 5-axis
manipulation strategy as not to cause
the exit jet damage the opposite sides
of the stringer. Figure 10 shows a
trimmed section from the end of a
stringer. A rate of 1 inch/min can be
used to cut through a 3-inch thick
section producing an acceptable
400-micro-inch surface finish.
A most challenging cutting application
is the cutting of composite honeycomb
Figure 10: Stringer end cut off
Page 16
December 2008
Federal Signal To Open Sixth FS Solutions Center In Gonzales, Louisiana
F
ederal Signal Environmental Solutions Group opened its sixth
FS Solutions center in Gonzales,
Louisiana on November 10, 2008.
The new center, located at 3111
S. Darla Avenue, will stock high
performance parts and accessories for
Federal Signal’s Jetstream brand of
waterblasters, as well as other makes
and models of waterblasters. The
FS Solutions center will also offer
customers the opportunity to rent or
to own equipment and will sell used
waterblasters.
“FS Solutions centers – like the
new Gonzales location – provide
the repairs, rentals, used equipment,
parts and accessories and training our
customers need to run their equipment
more profitably,” said Bryce Mulligan,
rental manager for FS Solutions. “For
customers interested in safety and
improved productivity, the Gonzales
FS Solutions center will offer
waterblast safety training.”
To help customers in Louisiana
and the Gulf Coast area with their
waterblast rental needs, the Gonzales
center is staffed by knowledgeable
employees with significant
waterblasting experience. A customer
looking for an extra waterblaster for
a short-term or seasonal contract can
choose from a full line of Jetstream
units at the new Gonzales center –
and FS Solutions will deliver the unit
directly to the jobsite. Additional
FS Solutions centers are located in
Birmingham, Alabama; Long Beach,
California; Houston, Texas; Toledo,
Ohio; and Streator, Illinois.
All FS Solutions locations provide
access to factory-trained, certified
technicians and genuine OEM parts.
“FS Solutions customers look to
our sales staff and service training
technicians for recommendations and
solutions to the unique challenges of
their particular applications,” Mulligan
said. “Whether it’s a contractor
looking for faster, more cost-effective
ways to perform cleaning operations
or a business that can benefit from
application expertise, equipment
evaluations or training, we’re
providing solutions.”
With nearly 100 years of collective
experience in industrial vacuum
loading, sewer and catch basin
cleaning, vacuum excavation and
industrial high-pressure waterblasting,
FS Solutions offers unsurpassed
expertise and a unique breadth of
product lines and trusted brands to
meet the needs of industrial cleaning
contractors and other industry
professionals.
For more information about products
and services available from the FS
Solutions centers or to find the nearest
location, call (800)627-3171, ext. 298,
or visit www.fssolutionsgroup.com.
Abrasive-Waterjet Machining of Composites, from page 16
Figure 11: Examples of Honeycomb Structures
Figure 12: Bottom Surface
of 25-mm-thick Honeycomb
Cut with an AWJ With and
Without a Lead Angle (9°)
December 2008
Page 17
as graphite epoxy with waterjets. This
problem is resolved when vacuum
assist and proper parameters are used.
Thousands of holes have been drilled
in carbon fiber composites without any
adverse effects. With proper process
timing, holes can be drilled rapidly.
While not as fast as laser, the holes are
typically of high integrity and good
surface finish. The AWJ process has
been successfully investigated for
rapid drilling (piercing) of holes in
composites. For example, the picture
shown in Figure 13 illustrated the
drilling of 0.40 inch holes in a 0.040inch thick composite material. The
drilling time
was about 0.9
seconds hole
to hole.
The pierced
hole size can
be controlled Figure 13: AWJdrilled holes in a
by selecting
carbon fiber composite
the process
panel (cover photo)
parameters
and the dwell
time. The larger the dwell time, the
larger the final hole size at the exit.
Accurate control over the dwell time is
needed to control the hole size within
certain tolerance limits. Another
interesting observation is that the
drilling time is improved by reducing
the water flow rate and increasing the
abrasive flow rate into the hole.
2.3.3 Emerging Applications
2.3.3.1 Turning
The turning of composite materials
results in significant problems
when using traditional turning and
grinding techniques due to the multidirectionality of the composite layup and its abrasiveness. OMCs are
typically not turned to produce parts,
but with the ability of the AWJ to
turn these materials, new designs may
Page 18
emerge using turned OMC
parts. While many composite
geometries have been turned,
this application will not be
discussed in this article.
2.3.3.2 Milling
The AWJ milling process is
conducted by traversing the
jets many passes close to each
other across the workpiece
surface. The multiple passes
of overlapping kerfs are used
to achieve controlled depth.
The milling of isogrid shapes
in graphite epoxy (Figure 14)
was conducted to demonstrate
the degree to which the depth
of milling can be controlled.
This approach involved the
use of steel masks. It was
found that depth control can
be accomplished to 0.001 inch
accuracy. The material can
be milled ply by ply if needed
suggesting its potential for
repair applications
Figure 14: AWJ-Milled Bosses (5 mm in
diameter) in Gamma Titanium Aluminide
In the repair application,
Figure 15: AWJ-Milled Scarf Joint in
damaged material is first
Graphite Epoxy
removed and then patched to
the original geometry. The
flexibility of AWJ cutting in a wide
in the AWJ process combined with
range of materials and shapes makes
advances in machinery and software
it suitable for the repair of composite
has made this technology acceptable
structures. Alternatively, the AWJ
for the aircraft industry. Today, all
could be used for milling off the
airframe manufacturers use AWJ for
damaged section or preparing the
trimming composites. There are still
patch. For example, the AWJ can be
needs for improved fixturing and AWJ
robotically scanned over the surface
producing a scarfed geometry suitable tooling cutting heads and end effectors
to address a wider ranger of parts
for repair as shown in Figure 15.
geometries and sizes. New software
and offline programming have been
critical to the acceptance of the AWJ
3. Conclusions
systems in the aircraft industry. 
The AWJ process for composite
trimming has now become a
mainstream process since it was first
introduced in the 1980s. Advances
December 2008
Jet Edge’s 90,000 psi X-Stream Waterjet Pump Increases Productivity Up To 50%
MEMBER
C
apable of producing pressures in excess of 90,000psi, Jet Edge’s new 100hp X-Stream xP90-100 waterjet
intensifier pump achieves much faster cutting speeds and
drastically lowers operating costs compared to traditional
60,000psi pumps, enabling users to increase productivity
and reduce part
costs.
The X-Stream
produces 50%
more pressure
than a 60,000psi
waterjet intensifier
pump, resulting in
a 40-50% increase
in productivity
for many materials. The X-Stream supports a 75,000psi
continuous operating pressure. Compared to a 60,000psi
pump, typical operating pressures of 75,000psi use 30%
less water, 30% less power, and up to 50% less abrasive,
resulting in a 40% reduction in operating costs. They
typically reduce taper by up to 0.001 inch. The X-Stream
is capable of producing flow rates of 1.45gpm and supports
up to a .017 inch orifice. Its fittings and tubing are rated
for 100KSI. The X-Stream is backed by nearly 10 years
of extensive research and development in hyper-pressure
technology.
For more information about the Jet Edge X-Stream
xP90-100 intensifier pump or other Jet Edge waterjet
equipment, visit www.jetedge.com, email: sales@jetedge.
com or call 1-800-JET-EDGE (538-3343).
Yellow Lube
A waterjet thread anti seize and thread lubricant that
stays on the threads longer and will not stain your
clothing or hands.
Proven in some of the
harshest Precision
Cutting and Portable
Waterjet environments. Available in
the larger 6 oz. tubes.
Come see us at www.tsmoly.com
under waterjet products.
December 2008
Recommended Practices for Manually
Operated High Pressure Waterjetting
Equipment
WJTA offers the Recommended Practices for the
Use of High Pressure Waterjetting Equipment in
English and Spanish. Topics include suggestions
for personnel qualifications, operator training, and
procedures for the proper operation of manually
operated high pressure waterjet equipment used by
the construction, maintenance, repair, cleaning and
demolition industries.
The Recommended Practices Safety Video, available
in CD-ROM or VHS, is the companion video to the
Recommended Practices for the Use of Manually
Operated High Pressure Waterjetting Equipment. The
video is a visual depiction of the major topics in the
Recommended Practices.
To place an order, see the WJTA order form for
publications/products on page 31 or contact the WJTA
office.
Page 19
definitely recommend Jet Edge to
other businesses. He said his systems
have been very reliable, are easy to
maintain and hold their tolerances very
well. He has the machines recalibrated
only once a year.
“We are so happy,” Gerke said. “The
ease of maintenance is excellent and
the reliability of the machine is second
to none.”
With its Jet Edge systems, G.O.
H2O is capable of cutting virtually
any material. In fact, they have cut just
about everything, from NHL logos on
pumpkins to 12-inch thick steel. The
company utilizes dual cutting heads
on about 70 percent of its projects to
double productivity.
G.O. H2O’s most recognizable
project can be seen at the Edmonton
International Airport. Over the course
of six months, the company cut 6,500
square feet of interlocking mosaic tiles
for 27 large swirl patterns that were
installed in the airport corridors.
“No matter who you talk to, if they
ask you what you have cut, you can
say, ‘have you been to the airport?’
and they all have seen the mosaics,”
Gerke said. “They do stand out.”
Gerke noted that one of his most
satisfying accomplishments was in
successfully performing a test cut
on .020-inch Pyrex® glass for a
technology company. The company
asked him to cut tiny rectangular
openings out of the 2x3-inch Pyrex®
pieces. They sent three sample pieces
to 20 waterjet shops and G.O. H2O
was the only shop that performed
a successful sample cut. G.O. H2O
got the project, and broke only three
pieces out of 120.
In another notable project, G.O.
H2O successfully separated a 30x48Page 20
G.O. H2O’s most recognizable project can be seen at the Edmonton International
Airport. Over the course of six months, the company cut 6,500 square feet of
interlocking mosaic tiles for 27 large swirl patterns that were installed in the
airport corridors.
inch, 12-inch-thick steel lifting lug by
using a large nozzle and slowing the
cut to 0.1-inch per minute.
“The customer had done all the
machining and they realized they
needed to separate it,” Gerke recalled.
“People said we couldn’t do it, but we
did it. It was a feather in our cap.”
G.O. H2O also has considerable
experience cutting 1x3-inch test
coupons of tough overlay materials
for the oil recovery industry, Gerke
noted. The coupons are typically steel
December 2008
StoneAge Introduces the Banshee BN33: A New Tube Cleaning Nozzle
S
toneAge has announced another addition to the Banshee family of
tools – the Banshee BN33. The new
Banshee is 33 mm in diameter and is
capable of 20K psi and up to 50 gpm.
The BN33 is suitable for tubes that are
1-1/2 inches to 2 inches in diameter.
The BN33 has a Universal
style head designed for polishing
and unplugging tubes at the
same time. As with all Banshee
tools the BN33 requires no
maintenance and is available
with a variety of inlet connections;
½-inch NPT, 9/16 MP, and BSPP.
The Banshee BN33 is designed to
replace the Marten (MT-P8) and
Ferret (FT-P4) Tube Nozzles. WJTAListServ - A Free Service To WJTA Members
The WJTAListServ enables
you to take advantage of prompt
email interaction with your
colleagues. WJTAListServ is a
FREE email broadcast system
developed by WJTA to help you
communicate and network with
other waterjet professionals.
stoneagetools.com or contact
StoneAge toll-free in the U.S. at
(866)795-1586, phone: (970)2592869, fax: (970)259-2868, or by email:
sales@stoneagetools.com.
Participation is limited
to WJTA members in good
standing. You must sign up
in order to participate. To
sign up for the WJTAListServ,
contact Beth at the WJTA
office by email: wjta@wjta.org,
phone: 314-241-1445, or fax:
314-241-1449.
WJTA Administration
Chairman of the Board
John Wolgamott
(970)259-2869
Vice-President
Pat DeBusk
(281)842-8000
President/Jet News Editor
George A. Savanick, Ph.D.
(952)432-7594
Treasurer
Larry Loper
(800)289-7447
Secretary
Hugh B. Miller, Ph.D.
(303)273-3558
2007-2009 Directors
Bill Gaff
(815)673-3835
Greg Galecki, Ph.D.
(573)341-4938
Mohamed Hashish, Ph.D.
(253)850-3500
Paul Webster
(281)925-4509
Bill McClister
(713)307-2142
Forrest Shook
(248)624-5555
B.T. Steadman
(601)933-4650
Emeritus Members
Andrew F. Conn, Ph.D.
(410)532-3452
Thomas J. Kim, Ph.D.
(401)874-5991
Thomas J. Labus
(262)245-9702
Fun-Den Wang, Ph.D.
(303)279-9415
Association Managers
Mark S. Birenbaum, Ph.D. l Kenneth C. Carroll
(314)241-1445
December 2008
Page 21
that has been overlaid with a very hard material such as
tungsten carbide or ceramic.
“The tar sands are full of sand and abrasive and they
are very hard on equipment so everyone and his dog
is trying to come up with a wear product to overlay on
steel,” he said. “We do a lot of overlay samples. We
have to slow them down to 0.1-inch per minute and
they are still difficult to cut.”
One of Gerke’s proudest accomplishments has been
figuring out a way to efficiently recycle the abrasive
material he uses in the majority of his jobs. Leave it to a
guy name Garnett to come up with an effective method
for reusing garnet.
“In our first two years [cutting 24/7], we had to shut
down every seven to ten days to clean out the tank,”
Gerke recalled. “We would be down 8 to12 hours. We
had a sump truck come in and pump out the tank and
haul the garnet off to the landfill. The first year, he
charged $400 per visit. Two years later, it was three
times the cost.”
After his second year in business, Gerke installed
a WARDJet abrasive recycling system to reduce his
downtime and counter rising landfill costs. He reclaims
50-70 percent of his garnet, and said the system paid for
itself within nine months. After he installed his second
waterjet system, Gerke came up with an ingenious way
to recycle garnet from both systems without having to
buy a second recycler. He equipped the second table
with a Jet Edge abrasive removal system with two sideloading dumpsters. After he fills one dumpster, it is
replaced with an empty dumpster. The full dumpster is
then dumped into the recycler. This allows him to keep
his new table up and running with no downtime. Once
a year, he cleans out the drops from both tanks.
To keep a good cutting edge, Gerke mixes his used
abrasive with new abrasive. He said has not noticed any
slowdown in cutting speeds since he started recycling.
For more information about G.O. H2O, visit www.
goh2o.com, email goh2o@telusplanet.com or call
1-877-43-GOH2O (434-6426). For more information
about Jet Edge, visit www.jetedge.com, email sales@
jetedge.com or call 1-800-JET-EDGE (538-3343). 
Page 22
Jet Edge Selected To Participate In
Minnesota’s Business Development Mission To Israel
J
et Edge International Sales Manager David J. Anderson
joined the Minnesota Trade Office’s Business
Development Mission to Israel, Dec.11-18, 2008. Anderson
is one of 30 business delegates who participated in the
mission led by Minnesota Gov. Tim Pawlenty. The
delegation’s objectives are to acquire market information
and business contacts, increase Minnesota exports to Israel,
facilitate high-tech exchanges and collaboration, and develop
strategic relationships with key organizations that support
U.S.-Israeli trade and investment.
As one of the world’s most prominent centers of innovation
and technology, Israel offers a wealth of opportunities for
high-tech exchanges and collaboration. Additionally, with
one of the best economic growth rates in the Middle East and
an affinity for American products, Israel presents significant
market opportunities for Minnesota exporters.
by PR Specialty Products, Inc.
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December 2008
Barton Mines Announces Expanded Capacity At HPX™ Processing Plant
B
arton Mines Company has
announced the expanded capacity
of their HPX™ waterjet abrasive
processing facility in North Creek,
New York.
The increased production is a
direct result of a comprehensive plant
re-engineering and expansion that
commenced in September 2007. “The
additional volume comes at a time
when demand for HPX has grown
exponentially,” says R. Randolph
Rapple, President.
be used in demanding applications
where other waterjet abrasives fall
short. In addition, Barton HPX™
waterjet abrasives are the cleanest
cutting media available. This
translates to less downtime due to
clogged jets or erratic abrasive feed
and a more cost-efficient operation.
Barton offers eight grades of
HPX™ waterjet abrasives. To learn
which HPX™ grade is best suited
for a particular application or to
order product samples, visit www.
barton.com, or contact Barton Mines
Company by email: info@barton.com
or call toll free: (800)741-7756.
Barton HPX™ high performance
abrasives have a unique structure that
produces sharp angular crystals. This
unusual trait enables Barton HPX™
to outperform all other waterjet
abrasives. The sharper, more angular
edges make HPX™ the fastest cutting
waterjet abrasive. Barton HPX™
produces a better edge quality and can
Guzzler Reintroduces Predator™ Liquid
Vacuum Tanker, from page 15
the American Society of Mechanical
Engineers boiler code, the tank also
complies with the U.S. Department of
Transportation specification DOT412
for hauling hazardous materials on the
highway.
“Industrial cleaning professionals
look to Guzzler for unique solutions
to their particular applications,” Lee
said. “We are proud to reintroduce the
Predator liquid vacuum tanker and
are confident that our customers will
appreciate our one-stop shop solution
to address their industrial cleaning
needs.”
For more information on the
Predator liquid vacuum tanker from
Guzzler Manufacturing, visit www.
guzzler.com or call (800)627-3171.
December 2008
Page 23
Maxpro Technologies Expands Houston, Texas, Operation
M
axpro Technologies has
announced the expansion of
Maxpro South, their Houston, Texas
operation, into the states of Louisiana,
Alabama and Mississippi.
This move will provide more direct
support to the water blast industry
in the region. Water blasting, oil and
gas and other industries that use the
Maximator line of high pressure
valves, fittings and tubing will benefit
from this increased technical support,
sales and service.
Kim Guidry, located in Lafayette,
Louisiana, has been appointed
technical sales representative to head
up this expansion. Guidry earned a
B.S. degree in Industrial Technologies
from the University of Southern
Louisiana and brings over 20 years
of experience in the high pressure
industry. He can be contacted at
(337)280-4223 or via email at kim@
maxprosouth.com.
Maxpro Technologies is the North
American distributor of Maximator
high pressure valves, fittings and
tubing as well as air powered products
including liquid pumps, gas boosters
and air amplifiers. Maxpro also
designs and manufactures various
standard and custom pressure systems
utilizing these Maximator products.
For more information visit us online
at www.maxprotech.com, or call
(814)474-9191.
The Jet News is published by the WaterJet Technology Association (WJTA)
and is a benefit of membership in the
Association.
©2008 Jet News. All rights reserved.
Reproduction in any form forbidden
without express permission.
Page 24
December 2008
Notes From Another SUPER-WATER® User:
Special thanks to Renato Lombari for the following notes:
I have worked with ultra-high pressure waterjets, operating up to 55,000 psi, for 19 years and SUPER-WATER® for 12 years. This
includes:
– plain water
– plain water + SUPER-WATER®
– plain water + abrasive
– plain water + SUPER-WATER® + abrasive
My work, during this time, gives an unambiguous demonstration of the economic advantages of using SUPER-WATER ® (1,2,3).
Relative to plain water, the addition of SUPER-WATER® to an ultra-high pressure waterjet cutting system:
–
–
–
improves the quality of cut (6) (An excellent example of this enhanced quality was published by Weber [1997].)
increases cutting speeds by 30% to 200% (non-abrasive cutting system)
reduces intensifier operating and maintenance costs by 38% (non-abrasive cutting system)
[from $11.12/hr (1993) to $6.86/hr (1996) = $4.26/hr reduction]
These results were for cutting fiberglass acoustical panels using an intensifier. My results also parallel those previously published for
precision cutting of natural-, synthetic-, silicone-, and foam-rubber (4) as well as synthetic materials such as Vistanex (5) and shoe
soles (4).
I have used SUPER-WATER® 100% of the time. Waste water and abrasive was disposed of without any problems. I have typically cut
the following materials:
–
–
–
–
–
304, 316 stainless steel
duplex stainless steel
aluminum (various alloys)
titanium
brass (various alloys)
–
–
–
–
–
clear float glass
laminated glass
slate
blue tempered steel
hot and cold rolled steel
–
–
–
–
marble and granite
acrylic
ultra-high molecular weight polyethylene
plywood, MDF and particle board
For a detailed analysis of abrasive cutting speeds and cut surface quality, please see the SUPER-WATER® groups file named
“Reduction in Abrasive Consumption.doc” posted 04/21/2002.
I have found that an approximate 0.1% to 0.2% SUPER-WATER® solution produces the following three-fold effects:
–
–
–
Reduces flow resistance due to substantial drag reduction.
Hoyt (1986) produced laboratory turbulent rheometer findings showing that even 9 ppm resulted in a 20% drag reduction and
Cobb and Zublin (1985) obtained a drag reduction of 54% in 2187 meters of 2.16 cm (0.85 inch) id coiled tubing.
Collimates the jet leaving the nozzle
Introduces macromolecular bombardment (Kudin et al., 1973) of polymer molecules dissolved in the water
REFERENCES
1. R. Lombari, “Ultra-High Pressure Non-Abrasive Polymer Jetting: A Production Environment Implementation,” Proceedings of the
9th American Waterjet Conference (Dearborn, Michigan: August 23-26, 1997), Paper 17, pp. 251-266.
2. R. Lombari, “Cutting Fiberglass Acoustical Panels,” Jet News, December 1995, p. 7.
3. R. Lombari, Letter to the Editor, ... “the longevity of our consumable jet components due to the lubricity of SUPER-WATER®,” Jet
News, November 1996, pp. 2 and 11.
4. W.G. Howells, “Polymerblasting with SUPER-WATER® from 1974-1989: a Review,” International Journal of Water Jet
Technology, Volume 1, Number 1, (March 1990), pp. 1-16.
5. W.G. Howells, “Additive Improves Abrasive Jet Cutting,” Jet News, December 1995, pp. 5 and 10.
6. D. Weber, Letter to the Editor, Jet News, February 1997, p. 12.
For more information and references, visit www.berkeleychemical.com, email: wglennhowells@webtv.net, or contact W.
Glenn Howells, Ph.D., President, Berkeley Chemical Research, Inc., Tel: 510-526-6272, Fax: 510-525-2375, Mail: PO Box 9264,
Berkeley, CA 94709-0264.
-ADVERTISEMENT-
StoneAge Upgrades the 40K psi Barracuda Cartridge
S
toneAge is offering an upgraded cartridge assembly that will retrofit
into existing 40K psi Barracuda, Gopher,
and SL tools and is being supplied with
all new tools as of November 20, 2008.
This upgrade is designed to increase the
operational life of the high pressure seals.
The following diagrams illustrate
how StoneAge is replacing the BC 405
Cartridge Assembly with the new BC 505
Cartridge Assembly. Several of the items
have changed. These BC 505 Cartridge Assemblies
became available on November 20, 2008.
If you have existing stock of the old
cartridge assemblies or the individual
parts, StoneAge will accept those unused
items for credit return. Visit www.
stoneagetools.com to download or print
these drawings.
StoneAge is continually working
to create new products and improve
existing products, and welcomes your
feedback about this upgrade and your
success with this product improvement.
Contact StoneAge toll-free in the U.S. at
(866)795-1586, phone: (970)259-2869,
fax: (970)259-2868, or by email: sales@
stoneagetools.com.
Page 26
December 2008
WJTA Welcomes New Members
Corporate
Stewart R. Browne
Manufacturing Co. Inc.
Alan R. Browne
James Browne
1165 Hightower Trail
Atlanta, GA 30350
Phone: (770)993-9600
Fax: (770)594-7758
IMS Maintenance Services
Maurice Duguay, Jr.
P.O. Box 6
Timmins, ON P4N 7C5
Canada
Phone: (705)235-9274
Fax: (705)235-8989
Moe Duguay, Sr.
979 Goldmine Road
Timmins, ON P4N 7C5
Canada
Phone: (705)264-1642
Fax: (705)235-8989
Trevor Niemi
Timmins Jacobile Wash
24 Hollnor Road
Porcupine, ON P0N 1C0
Canada
Keith Huber, Inc.
Alan Klaser
14220 Highway 49 North
Gulfport, MS 39503
Phone: (228)832-0992
Fax: (228)832-2068
Kroy Industries, Inc.
David D. Le Duc
Phillip Seever
522 W. 26th Street
P.O. Box 309
York, NE 68467
Phone: (402)362-6651
Fax: (402)366-6566
Albert Reyna
5223 89th Street
Lubbock, TX 79424
Phone: (806)798-2015
Fax: (806)798-2018
Corporate Alternates
Stephen Davis
KMT Aqua-Dyne, L.P.
3620 West 11th Street
Houston, TX 77008-6004
Phone: (713)864-6929
Fax: (713)864-0313
December 2008
Pedro Hans Dominguez
TNT High Pressure
Waterworks, Ltd.
9451 49th Street
Edmonton, AB T6B 2L8
Canada
Phone: (780)469-4073
Fax: (780)463-2077
Rex Foster
Prepcon, Inc.
6737 Dogwood Road
Baltimore, MD 21207-4121
Phone: (410)265-6722
Fax: (443)200-1010
Chris Kay
Super Products LLC
17000 W. Cleveland Avenue
New Berlin, WI 53151-3593
Phone: (262)784-7100
Fax: (262)784-9561
Greg Loraine
DYNAFLOW, Inc.
10621-J Iron Bridge Road
Jessup, MD 20794-9381
Phone: (301)604-3688
Fax: (301)604-3689
Jonathan Lukas
HydroChem Industrial
Services, Inc.
900 Georgia Avenue
Deer Park, TX 77636-2518
Phone: (713)393-5624
Fax: (713)393-5959
Iris Montemayor
Nuova Fima, USA
15255 Gulf Freeway
Suite 148D
Phone: (281)464-0500
Fax: (281)464-0506
Alfredo Sanchez Oviedo
Representaciones Industriales
JBL S.A. de C.V.
Gomez Farias #1957
Col: Flores Magon
Veracruz, Ver. 91900
Mexico
Phone: [52](229)932-5672
Fax: [52](229)932-6278
Brian Ritchie
Denholm Oilfield
Services UK, Ltd.
Greenbank Place
East Tullos Industrial Est.
Abedeen, Scotland AB12 3BT
United Kingdom
Phone:[44](1224)248600
Fax: [44](1224)248032
Stefano Roti
Pratissoli Pompe
Via Enrico Fermi 25
S. Ilario d’ Enza
Reggio Emilia 42049
Italy
Phone: [39](522)904311
Fax: [39](522)904444
Arnie Salinas
GMA Garnet (USA) Corporation
480 N. Sam Houston Pkwy E
Suite 130
Phone: (832)243-9300
Fax: (832)243-9301
Tom Sanders
KMT Aqua-Dyne, L.P.
3620 West 11th Street
Phone: (713)864-6929
Fax: (713)864-0313
Rene Stuehlinger
BHDT GmbH
Werk-VI-Strasse 52
Kapfenberg A-8605
Austria
Phone: [43](3862)303-315
Fax: [43](3862)303-304
Ulrich Thomas, Ph.D.
Aqua Drill International
1300 FM 646 East
Dickinson, TX 77539-3022
Phone: (281)337-0900
Fax: (281)337-7270
Matthew Verghese
Hydrolink FZE
Jebel Ali- Headquarters
PO Box 18502
Dubai
United Arab Emirates
Phone: [971](4)8861414
Fax: [971](4)8861413
Individuals
Marcos Requena Arcajo
Ingenieria Y Plantas
De Proceso S.L.
Parque Empresarial Principado
De Asturias Avda. del Zinc s/n
Primero - Oficina nº2
Avilés, Asturias 33400
Spain
Phone: [34](98)5514476
Fax: [34](98)5514477
Eric Bieberich
Fort Wayne Wire Die, Inc.
2424 American Way
Fort Wayne, IN 46809-3005
Phone: (260)747-1681
Fax: (260)747-4269
Frank Blaine
Kitchell Environmental Services
1707 E Highland Avenue
Phoenix, AZ 85016-4640
Phone: (602)222-5300
Fax: (602)264-9296
Allan Cox
Atlantic Industrial Cleaners
11 Brown Avenue
Dartmouth, NS B3B1Z7
Canada
Phone: (902)468-9011
Fax: (902)468-5977
Rob Haviland
Crowe Manufacturing
216 S. Torrence Street
Dayton, OH 45403-2625
Phone: (937)254-4441
Fax: (937)254-4475
Ignacio Lastiri
Vialven SA
Mirave 2742
Buenos Aires C1281ABB
Argentina
Phone: [54](11)4303-3415
Fax: [54](11)4303-3417
Henry Yang
Semlima Industrial
Company, Ltd.
19, 36th Road
Taichung Industrial Park
Taichung 40700
Taiwan, Republic of China
Phone: [886](4)23550190
Fax: [886](4)23550196
Best wishes for a
Happy, Healthy
and Safe New
Year from the
WJTA Officers,
Board of
Directors & Staff
Page 27
Jet Edge Introduces Easy-to-Use CAD/CAM Nesting Software For Waterjet Cutting
J
et Edge is now offering the easy-to-learn and use SigmaNEST
Companion™ CAD/CAM nesting
software on its precision waterjet
cutting systems.
Developed by SigmaTEK Systems,
LLC, of Cincinnati, SigmaNEST
Companion uses a wizard-based
approach to allow waterjet operators
with little or no CAD/CAM
experience to design, edit and nest
parts quickly with little training.
Available at a fraction of the cost
of the full SigmaNEST program,
Companion features numerous
SigmaNEST functions such as DXF
import, TrueShape nesting, automatic
Page 28
path generation, and NC code
generation. With it, waterjet operators
can load DXF files to automatically
or manually nest parts. They also can
create new tasks using standard shapes
available in the program’s library.
Companion also allows operators to
edit part parameters and generate a
variety of custom reports, including
cost, layout and summary reports.
Jet Edge manufactures a full line of
precision waterjet cutting machines,
intensifier pumps and waterjet parts.
Jet Edge waterjet tables are available
in a wide range of sizes, from 30
inchesx30 inches to 30 feetx100 feet.
Jet Edge waterjet intensifier pumps
are capable of producing pressures
from 30,000psi to 90,000psi. They
are available in electric and diesel
models ranging from 30hp to 280hp.
Jet Edge’s open-architecture motion
controllers are compatible with most
CAD/CAM software, including
SigmaNEST and SigmaNEST
Companion.
jetedge.com, call (800)JET-EDGE
(538-3343) or email sales@jetedge.
com. For more information about
SigmaNEST, visit www.sigmanest.
com, call (513)674-0005 or email
sales@sigmanest.com.
December 2008
2009 American WJTA Conference And Expo
August 18-20, 2009
Marriott Houston Westchase Hotel  Houston, Texas, USA
Announcement and Call for Papers
Impressive progress and a fast-growing understanding of the diversified applications of waterjet technology are generating a growing excitement
in the industry. New techniques and applications are being developed and current ones are being improved. Waterjet technology, now being used in
nearly all types of industry — manufacturing, mining, construction, concrete, stone, aerospace, engineering, oil and gas, power plants, process, and
medical industries — continues to expand at a rapid pace.
The 2009 American WJTA Conference And Expo will focus, from a practical and scientific viewpoint, on the most up-to-date advances in
waterjetting equipment, techniques, and applications. The areas to be addressed include, but are not limited to:











Abrasives, Water, and the Environment
Advanced Industrial Applications
Advances In High Pressure Technology and Equipment
Automotive and Aerospace Applications
Cleaning and Coating Removal
Components and Systems
Construction and Non-Manufacturing Applications
Contractor Applications and Processes
Demilitarization, including Removal of Land Mines (Demining)
Drilling Applications
Excavation, Tunneling, and Mining Applications











Hydrodemolition
Hydroexcavation
Jet Mechanics and Visualization
Jet-Material Interaction
Manufacturing Processes
Market and Future Needs
Novel Jets and Applications
Process Modeling and Control Studies
Rock Cutting
Safety, Training, and Environmental Protection
Vacuum Equipment
Commercial and academic authors are encouraged to submit titles and abstracts for consideration. To submit an abstract(s), please complete the
abstract submission form on the back of this sheet, attach a copy of your abstract(s), and forward to the attention of the Conference Coordinator at
the WaterJet Technology Association. An electronic submission form can be found on the WJTA web site at www.wjta.org. The deadline date for
submission of abstracts is January 15, 2009.
An Abstract Review Committee consisting of five referees will review the abstracts. Authors will be advised by February 27, 2009, regarding the
decision of the Abstract Review Committee.
The 2009 American WJTA Conference And Expo is organized by the WaterJet Technology Association. The WaterJet Technology Association
looks forward to providing this forum and to your involvement and participation.
Authors - Please Note
Papers must be original.
Papers must not have been published elsewhere or be pending publication.
Publication Fee.
A nonrefundable publication fee (equal to the price of a member Full
Conference registration) is required. This publication fee will be waived if at least one author registers (Full or Combo) for the WJTA Conference. (Authors must
pay the applicable member or nonmember price.) Also, one registration is good for multiple papers. The deadline date for receipt of your final paper will be May 4, 2009. The publication fee or payment for a Full or Combo registration is due no later than
June 15, 2009. Your paper will not be included in the Proceedings if the publication fee
or registration fee is not paid by this date.
Papers and presentations must be in English.
Papers should be no longer than 15 printed
pages. A “Paper Guide” containing directions for submitting papers will be forwarded to
you after your abstract is accepted. Papers that do not follow the “Guide” will be returned
to the author(s) for correction(s) or charged a fee for revisions made by the WaterJet
Technology Association office.
Papers should be free of
commercialism.
Papers should be submitted as a Word file and a PDF file.
2009 WJTA Conference Committee
Pat DeBusk
Co-Chairman
DeBusk Industrial Services Company
Bill McClister
Co-Chairman
Veolia Environmental Services
Mohamed Hashish, Ph.D.
Editor
Flow International Corporation
Bill Gaff
Jetstream of Houston, LLP
Hugh B. Miller, Ph.D.
Colorado School of Mines
Gary Noto
Veolia Environmental Services
B.T. Steadman
Vacuum Truck Rentals, LLC
2009 American WJTA Conference And Expo
August 18*-20, 2009

Marriott Houston Westchase Hotel

Houston, Texas
Abstract Submission Form
For each paper to be submitted for consideration, please complete this form, attach a copy of the abstract, and mail or fax to WJTA by
January 15, 2009. An electronic submission form can be found on the WJTA web site at www.wjta.org. Authors will be advised by February 27, 2009, regarding the decision of the Abstract Review Committee.
Paper Information
Paper Title ________________________________________________________________________________
Authors __________________________________________________________________________________
Contact Person
(Please print or type)
Name____________________________________________________________________________________
(First Name)
(Surname/Family Name)
Position/Title_______________________________________________________________________________
Company/Organization ______________________________________________________________________
Street Address_____________________________________________________________________________
City, Province______________________________________State ___________________________________
Country___________________________________________ Zip/Postal Code__________________________
Business Telephone ______________________________ Fax ____________________________________
Email__________________________________________ Web site_________________________________
Signature_____________________________________________________ Date _______________________
Please check the category that best describes the general nature of your paper.  Applications
 Research
Key words (Check the boxes under the different categories that apply to your paper):
Type of Study
 Modeling
 Experimental study
 Hardware development
 Contractor case study
 Manufacturing case study
 Software development
 Economic analysis
 Legal and Safety
 Other _______________
Process
 Cutting
 Drilling
 Surface preparation
 Cleaning
 Stripping
 Safety
 Milling
 Jet-assisted
 Other _______________
Related Industry
 Generic
 Shipyard
 Mining
 Construction
 Aerospace/Aircraft
 Automotive
 Oil/Gas/Refinery
 Quarrying
 Other _______________
Jets







Material
 Metal
 Rock
 Glass
 Ceramic
 Composite
 Concrete
 Other _______________
Environment
 Field work
 Factory work
 Submerged
 Nuclear
 Demilitarization
 Offshore
 Other _______________
Waterjet
Abrasive-waterjet
Abrasive suspension jet
Pulsed
Cavitation
Polymer Jets
Other _______________
*August 18 is reserved for the short course(s).
Mail completed form and abstract, NO LATER THAN JANUARY 15, 2009, to: Conference Coordinator, 2009 WJTA American Waterjet Conference, WaterJet
Technology Association, 906 Olive Street, Suite 1200, St. Louis, MO 63101-1448, USA, telephone: (314)241-1445, fax: (314)241-1449, email: wjta@wjta.org,
web site: www.wjta.org
WaterJet Technology Association's Order Form for Publications/Products
THREE EASY
WAYS TO ORDER
Name ________________________________________________ Member # _____________
Payment Method
Company ____________________________________________________________________
Address ______________________________________________________________________
Check or Money Order payable to WJTA
(U.S. DOLLARS ONLY)
City ____________________________________________________ State _______________
PO # ___________________ (Enclose PO)
Country ________________________________________ Postal Code __________________
Please charge my MC VISA
AMEX Discover
Credit
Card # ______________________________
Phone # [
](
) __________________ Fax # [
](
)_____________________
Email_________________________________________________________________________
(to receive shipping confirmation)
Exp. Date_____________________________
Billing Address (if different from above):
Address ______________________________________________________________________
City ____________________________________________________ State _______________
_____________________________________
Print name as it appears on card
_____________________________________
Cardholder's signature
Country ________________________________________ Postal Code __________________
WJTA
Member Price
Proceedings CD-ROM of The 2007 American WJTA Conference And Expo
Proceedings CD-ROM of The 2005 WJTA American Waterjet Conference
An Overview of Waterjet Fundamentals And Applications, Fifth Edition (2001)
An Overview of Waterjet Fundamentals And Applications
@
@
@
@
@
@
$
$
$
$
$
$
____ Waterjet Technology: Basics and Beyond (8/19/07 PowerPoint presentations in printed format)
____ Waterjet Technology: Basics and Beyond (8/21/05 PowerPoint presentations in printed format)
@
@
$ 20.00
$ 20.00
____
____
____
____
____
____
(8/17/03 PowerPoint presentations in printed format)
10-08
Non Member
Price
109.00
35.00
35.00
10.00
55.00
30.00
$
$
$
$
$
$
129.00
55.00
55.00
30.00
70.00
35.00
$ 25.00
$ 25.00
By Phone: Just call
(314)241-1445 and have
your credit card information
ready. (MC/VISA/AMEX/
Discover ONLY).
By Fax: Fill out the order
form with your credit card
information and call our 24hour fax number at:
(314)241-1449.
By Mail: Fill out the order
form and mail with
applicable payment to:
WJTA, 906 Olive Street,
Ste. 1200, St. Louis, MO
63101-1448.
Shipping &
Handling
$
$
$
$
$
$
8.00
8.00
8.00
8.00
8.00
8.00
$ 8.00
$ 8.00
=
=
=
=
=
=
$_______
$_______
$_______
$_______
$_______
$_______
= $________
= $________
Minimum charge of $8 per order. $8 for 1-3 items purchased; $16 for 4-7 items purchased; for 8 or more items purchased, contact the WJTA office.
Waterjet Equipment Recommended Safety Practices. Specify: English Edition or Spanish Edition
Vacuum Equipment Recommended Safety Practices. Specify: English Edition or Spanish Edition
1 - 10 copies
11 - 99 copies
100 - or more copies
_____ # of copies
_____ # of copies
_____ # of copies
x
x
x
$
$
$
7.00 ea.
6.00 ea.
5.00 ea.
Shipping & Handling of Recommended Safety Practices
1-10 copies .... $0.50 per book, 11-99 copies ....... $0.40 per book, 100 - or more copies .. $0.25 per book
$ 12.00 ea.
$ 10.00 ea.
$ 8.00 ea.
= $_______
= $_______
= $_______
____ # of copies x $_______
= $_______
Waterjet Equipment Recommended Safety Practices Video. Specify: VHS Video or CDROM
Vacuum Equipment Recommended Safety Practices Video. Specify: VHS Video or CDROM
1 - 4 copies
5 - 10 copies
11 - or more copies
_____ # of copies
_____ # of copies
_____ # of copies
x
x
x
$ 49.95 ea.
$ 39.95 ea.
$ 29.95 ea.
$ 99.95 ea.
$ 89.95 ea.
$ 79.95 ea.
$ 6.00*
= $_______
= $_______
= $_______
Shipping & Handling of Safety Video .................................................................................................................................................................................................. = $_______
*Contact the WJTA office for the shipping & handling charge of more than one Safety Video.
Baseball Cap
WJTA Decals. Minimum
5” decals
3.5” decals
2” decals
_____ # of caps
$5 order includes shipping and handling.
4 for $5, additional decals .50 each
WJTA Executive Organizer
WJTA Navy Blue Polo Shirt
Size _____ (S, M, L, XL, 2X)
x
$
7.95 ea.
$
7.95 ea.
$ 6.00 ea.
_____ # of decals
_____ # of decals
_____ # of decals
= $_______
= $_______
= $_______
= $_______
_____ # of organizers
x
$ 20.00 ea.
$ 30.00 ea.
$ 8.00 ea.
= $_______
_____ # of shirts
x
$ 30.00 ea.
$ 35.00 ea.
$ 7.00 ea.
= $_______
Spanish
Waterjet Safety Cards. Specify: English
1-10 safety cards
_____ # of cards
x
.30 each
.50 each
11-99 safety cards
_____ # of cards
x
.25 each
.45 each
100-249 safety cards
_____ # of cards
x
.20 each
.40 each
250+ safety cards
_____ # of cards
x
.17 each
.35 each
Shipping & Handling of Safety Cards: 1-50 cards FREE (For the purchase of more than 50, call the WJTA office for the shipping & handling charge.)
For shipping and handling charges outside the USA, contact the WJTA Office.
TOTAL ENCLOSED
=
=
=
=
=
$
$_______
$_______
$_______
$_______
$______

Abrasive-Waterjet Machining Of Composites

Transcription

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